Classification of Confectionary Products : -

Classification - I

1. Chocolate type confectionary product2. Solid3. Solid with inclusion4. Enrobed or moulded with candy, fruit, nut or granola centre5. Enrobed or moulded with a bakery product eg. wafer inside chocolate6. Panned7. Assortment and others

b) Chocolate (same)c) Non - Chocolate Confectionary producti) hard candyii) chewy candy (including granola bar)iii)soft candyiv) iced/coated candyv)Pannedvi)licorice type

d) gum basedChewing gum, bubble gumi) containing sugarii) not containing sugar

Sugar Confectionary Traditionally in India confectionary has meant barfi, chikki and the like which are available in the un ordanized sector but in market, confectionary means Western Confectionary which was introduced in India through Traders from the west through the Silk Route and through invaders from west including the British. Sugar confectionary fundamentally is a solution of sugar and liquid flucose cooked with desired consistency followed by addition of colors, flavors and optional ingredient based on desired product type. it can be a hard boiled confectionary or may be toffee or it could be an eclair or lozenges and so on. It might be interesting to note that conady word used to refers to confectionary product derived from Arabic word ʻQandeʼ which means sugar confectionary.

Confectionary Composition Essential ingredients are like water, sugar, liquid glucose and optional ingredients provide value addition to confectionary product rendering them a richer, a premium status in terms of appearance, taste, mouth feel.

Sensory Analysis Color, flavor, after taste, use of optional ingredients are all governed by the Indian Food Law. The PFA Act 1954. Hence one needs to thoroughly verify legal compliance before choosing ingredients. Needless to mention all the ingredients used in our products have total legal compliance. There are variety of optional ingredients that could be used in confectionary product dependency on the product type.

The following are some of the key optional ingredients used -i) Milk and Milk Products - Butter, Creamii) Fats & Oils - Milk fat, Vanaspati, and other kinds of vegetable oil depending on product

category, richness required of the productiii)Flavor - Probably most important from the point of view of product quality and oral

gratification. The flavor could be natural or nature identical or syntheticiv)Color - From an aesthetic component of product, the colors are added to associate a

product to a particular flavor. eg in an orange flavored candy we add orange color and so on.

v)Acidulants - Food acids like citric acid, malic acid etc which are used to give tangy or sourness to the product. These are mainly used for fruit flavored candies like orange, lemon flavor etc.

vi)Emulsifiers - Special fats used in fat based formulation to facilitate uniform mixing of fat with water base. Thereby insuring where a uniform distribution in final product.

vii)Buffer agents - Used in acid base formulations to guard against sugar acid level which would cause inversion or break down of sugar which cause stickiness of sugar.

Raw Materials Sugar is one of the essential ingredients in any type of confectionary product. Functionally sugar acts as sweetening or bulking agent. In India, the sugar generally comes from sugar cane. Crushing the ripe sugar cane and extracting itʼs juice to manufacture the sugar. The juice is then bleached used SO2, concentrated into a viscous liquid and finally the sugar crystallization is by centrifugation. The most important parameter in the level of bleaching which determines the whiteness of sugar and thereby product quality. The commercial sources of sweet beverage or confectionary depends greatly on uniformity texture and distinctive taste and then depends greatly on the sweetening agent. The presence of certain non-sugar solids in trace amounts can completely make certain beverage or confectionary. For this reason the beverage flavors and confectionary industry demands a truly natural sweetener which is available in most perfect form as highly standardized liquid sugar.

1. Dry sugar2. Invert Sugar3. Liquid Sugar4. Sucrose / Fructose5. Mishri6. Khandsari7. Bura Sugar8. Refined Sugar9. Beet Sugar

The relative sweetness of several natural substance to sucrose - 100

Fructose - 173Invert Sugar - 130Glucose - 74Sorbitol - 60Mannitol - 50Xylose - 40Mallose - 32Galactose - 32Rafinose - 23

Lactose - 16

The most important ingredient is liquid glucose which is called the heart of confectionary because there can be no sugar confectionary without Glucose. Functionally, liquid glucose acts as a doctoring agent meaning it binds and holds the sugar and prevents in transforming by recrystallization during cooking. It is commonly derived from tapioca or maize starch. The process involves the crushing or slurring of tapioca ships with water and extracting the milk. The starch milk is then digested (either enzymatically, or acid digestion) bleached, desalted, concentrated to a viscous mass which is liquid glucose.

Sucrose Made from sugar cane or sugar beat, sugar is one product that is 89.9% pure . It has no vitamins, no minerals and no undesirable ingredients and no impurities. Pure sucrose, carbohydrate energy. There are very fine, fine, superfine, extra fine, light brown, medium brown and dark brown, free flowing brown and soft brown sugars. There are confectioners sugars, hastess tablets, crystal tablets and dots and there are totally organix raw sugar. All white granulated sugar are almost identical. it is a highly refined product with no flavors except sweetness. it has about 180 cal/teaspoon and no nutritive quality. Sweetness of granulated sugar due to crystal size and method of processing which means larger the crystal, purer the sugar. The brown sugar is white sugar with molasses added. In conventional type whether they are light, medium, dark brown, soft and moist. They have same sweetening power as white sugar. But they have definite flavors that is desirable with some grains. Although many people think brown sugar is more nutritious than white. It has same nutritional value and it has undergone the same degree of refining. Sucrose is a di sacchride sugar and is one of the most important ingredients. Probably the least understood about itʼs many properties and reactions. Sucrose is practically never used alone but in combination with other ingredients with which it may react. Sucrose is inherently acidic in nature. This is enhanced at high temperatures. It is highly unbuffered. Only trace amounts of ash is present. Presence of trace natural salts such as NaCl, Mg, K2HPO4 tend to increase inversion. Alkaline salts such as NaHCO3, NaKCO3 minimize inversion but increase color while nitrogen compounds (ammonia salts, amino acids, amides) increase both inversion and color. The latter through the mallard browning reaction. Further more the alkaline salts, sodium carbonate, NaHCO3 cause a browning reaction, apparently through the composition of reducing sugar form and MgCl results in increasing inversion. Sucrose is non-reducing and doesnʼt form color unless inversion takes place. Forming the chemically reactive mono sacchrides, dextrose and fructose. The latter being more reactive and heat sensitive. This applies to reaction in solution and thermal decomposition on reactions to high temperature. When sucrose is dissolved in water, several effects occur. The most important of them are :-1. Increase in viscosity2. elevation in boiling point3. increased osmotic pressure4. heat of solution and all of these affects the products.

Structures of Sucrose, Glucose and FructoseSUNIL

In fact it is almost twice as sweet as sucrose. The cone or beet sugar is widely used to manufacture sucrose. Fructose also known as Levulose or fruit sugar.

Hygroscopicity - Crystalline fructose is very hygroscopic and also are concentrated solutions. Handling of pure fructose as an ingredient in chocolate production for instance, needs special preparation to prevent moisture pick up. Inclusion of fructose in high moisture confectionary centreʼs will retard drying but with low moisture produce such as hard candies that reverse applies. Inversion of the sucrose in hard candies which produce some fructose is detrimental induces stickiness.

Browning - Fructose being a reducing sugar will develop brown pigments on heating and it is very active in mallard reactions with milk protein. This is a factor that affects flavor intensity in caramel.

Apple - 6.35 % FructoseRaisin - 32 %Grape - 5.3 - 9.5 %Fig - 21.5 %Beet Sugar - 50 %Invert Sugar - 50 %

The relative sweetness of sugar and other sweetening agent may differ according to the method of measurement. The presence of other materials, the salt may increase or decrease the apparent sweetness depending on the concentration and type of food and drink tested.

Cane or beet is a compound of two simple sugars, glucose and fructose. Glucose also called dextrose is the principle component of starch and corn syrup. It is glucose which is abnormally metabolized by person suffering from diabetes. Fructose however requires no insulin for itʼs metabolism and diabetics can use it in an internally normally (essentially) normal manner. 50-80 g are tolerated by diabetic. Fructose is used in medicine as a course of quick energy and as in metabolic stimulant for variety of diseases and for abnormal conditions. Fructose is not an additive not a drug. It is food.Fructose has a sparing effect on protein and it increases the rate of metabolism of alcohol and has been used to treat severe alcoholism. Fructose has been recommended as a rapid source of energy to athletes as means of combating fatigue. Since the principle source of fructose is derived by fermentations, oxygen of glucose, part of invert sugar, fructose and sodium gluconate are readily available intermediates in combination. Fortunately, both components of this mixture increase the sweetness and decreases the objectionable after taste of saccharin making the combination very suited to artificial sweetened product or low calorie product. An increase of at least 35% of sweetness of saccaharine has been reported when it i s used with fructose and gluconate mixture. A combination of 0.01 gm of saccharine and 1.0 g fructose will produce the sweetness level of 7 sucrose in 1/7Th bulb and has only 1/7th calorie. This assumes saccharin is 500 times sweeter than sugar. The sweeteners ratio is variously given 300-700 times greater. Combination of fructose and gluconate with or without saccharine should be applicable to soft drink formulation because this can produce sweetness, buffering power and acidity decreases and calories often at less cost.The combination is also applicable inexpensive sweeteners with legal medical advantage also. High fructose corn syrup (HFCS) containing 42% fructose, 51 % dextrose and having a sweetness = to that of sucrose. Sweeter than dextrose and slightly less sweeter than medium invert sugar. it is produced from dextrose by enzymatisation is less color stable

then most syrup and has a synthetic effect on synthetic sweeteners such as saccharine HFCSis sweeter than a comparable solution of sucrose when both contain the same amount of sodium saccharine. HFCS can be used in practically every food in which liquid sucrose or medium or totally inverse sugar is highly employed HFCS is have been commercially utilized in confectionary and carbonate beverages, fountain syrup and caramel food. HFCS is worked to about 5-6& more in solids than in a liquid. So it has a higher osmotic pressure. Honey means the food derived entirely from the work of bees operating upon the nectar of flowers and other sweet exudation of plants. It shall not contain more than 25 % of moisture, 0.5 % ash and 5 % sucrose except in the case of Carbia Callosa and honey dew where it shall be 60 % Fructose to Glucose ratio shall be 10 % The minimum reducing sugar content (expressed as invert sugar) shall be 65 % except in the case of Callosa and honey dew where it shall be 60 % Glucose to fructose ratio shall not be less than 0.95 %

Cube Sugar Means the sugar in the form of cube or cuboid blocks. Manufactured from refined crystalized sugar. It shall be white in color, free from dirt and other extraneous contamination. It shall conform to the following standards : -

Sucrose - Not less than 99.7 % by weightMoisture - Not more than 0.25 % by weightTotal Ash - Not more than 0.03 % by weightSO2 - Not more than 70 ppm`

Dextrose - It is a white or light cream granular powder. Odorless and having a sweet taste. When heated with potassium Cupric Tartarate (when Fehlingʼs A and B are put in sugar, we get this) it shall produce a precipitate of cuprous oxide. It shall conform to the following standards : -

Sulfated Ash - Not more than 0.1 % on dry basisAcidity - 0.5g dissolved in 50ml of freshly boiled and cooled water required for neutralization and not more than 0.20ml of N/10 NaOH to Phenolphthalein indicator. Glucose - Not less than 99 % on dry basis.

SO2 - Not more than 70ppm

Golden syrup - It is the syrup obtained by the inversion of sugar. It shall be golden yellow in color. Pleasant in taste and free from any crystallization. It shall conform to the following standards : -Moisture - not more than 25 % by weightTotal Ash - not more than 2.5 % by weightTotal sugar as invert sugar - not less than 72 % by weightSO2 - shall not exceed 70ppm

Sodium bi carbonate used for clarification purpose shall be of Food Grade quality. Sorbitol - It is a polyhydric alcohol and is widely distributed in nature. Sources - Mountain ash berry and produced by chemical reduction of glucose. Sorbitol is a valuable substance in the manufacture of diabetic chocolates and confectionary because unlike some intense sweeteners it has bulk as well as sweetness. It is available commercially in crystalline and syrup form. The crystalline is used for chocolate manufacture. The liquid form is used in

various forms including confectionary as a softener and it will help to prevent drying out. It is used in the manufacture of sugar less confectionary and chewing gum.

Sorbitol is polymorphic and exist in three crystalline states. Only one form ie Gamma form is stable. The other unstable forms under the influence of moisture or heat transform into the stable form. Equilibrium Relative Humidity - Sorbitol syrup because of itʼs viscosity has an effect in some formulations of retarding crystallization. In such cases it would convey extra humictant properties to the confections as well as softening the texture. Manufacturers of sorbitol publish data on the ERH of solutions of different strength but when used in any ingredient with humictant properties, it is necessary to examine itʼs effect in the finished product and this apply to sorbitol. Sorbitol has a marked cooling effect when taken into solution and also has a high solubility.

Optional Ingredient Milk Products :-

Milk can be in the form of condensed milk, skimmed milk, whole milk powder, butter, ghee etc they are added to impart richness, body and natural caramel flavor to the confectionary. When milk products are added, protein and sugar in the milk solids react with each other and leaves a smooth feeling in the mouth. You will notice that most of confectionary products contain milk butter. These have a dwell role of providing rich buttery taste flavor and smooth mouth feel to the product. There are other options like hydrogenated vegetable oil, which is commonly used in confectionary. There is palm kernel oil which is imported and used. Fats usually added to improve the body and smoothness of the product.

Acidulant - It could be citric acid, malleic acid of fumaric acid. The main function of the acidulants is to give tanginess to the fruit flavored product.

Flavors - Flavors are very important ingredients in confectionary products as they act as a key differentiator of product. The prefix orange candy or mango candy is based on the flavor used. It is very important that the flavor is stable throughout the shelf life of the product. There are three types of flavors -

1. Natural oils like ginger oil or eucalyptus oil. These are extracted directly from the natural raw materials.

2. Nature identical - these are flavors which are available naturally but can also obtained from other natural sources. For example vanillin which is obtained from vanillin plant. This can also be extracted from cellulose present in paper.

3. Synthetic flavor - These are combinations of chemicals such as esters and aldehydes which have characteristic odor of different fruits and other flavor notes in sugar will alter not only the flavor but color, consistency and stability of a beverage.

Advantage of using liquid sugar : -

1. Liquid sugar can be unloaded from the delivery truck or car and moved from the storage tanks to the syrup room with minimum labour requirement.

2. Since the liquid syrup is in solution, the time required for making syrup is reduced.3. The quality of bottle grade liquid sugar is equal to the quality of bottle grade dry sugar. 4. Due to the elimination of bags and cost of packaging, liquid sugar is usually lower in

price than dry sugar.

Non nutritive sweeteners : -

Ammonium SaccharinCalcium Cyclohexyl SulfamateCalcium Saccharin Magnesium Cyclohexyl SulfamatePotassium Cyclohexyl SulfamateSaccharin Sodium Cyclohexyl SulfamateSodium Saccharin

PFA Specification of Sweetening Agent

Plantation White Sugar (commonly known as sugar means the crystallized product obtained from sugar cane or sugar beet. It should be free from dirt, filth and iron fillings and added coloring matter. Extraneous matter if present shouldnʼt exceed 0.1 % by weight. It should also conform to the following standards : -

a) Moisture (when heated at 105 + - 1 degree celsius) Not more than 0.5 % by weight

b) Sucrose content Not less than 98 % by weight c) Ash content ! Not more 0.01%! d)(So2 shall not exceed 70 ppm) ! ! ! ! ! ! ! # # # # ! ! !! ! ! !Refined sugar means white crystalline sugar obtained by refining Plantation Wide Sugar which has been free from dirt, filth and iron fillings and added coloring matter.

Extraneous matter shall not exceed 0.1% by weight. It shall also conform to the following standards : -

a) Moisture (when heated at 105 + - 1 degree celsius for three hours) Not more than 0.5% by weight

b) Sucrose Not less than 99.5 % by weightc) Ash content not more than 0.01 %

Khandsari Sugar (obtained from sugarcane juice by open pan process. May be of varieties namely - Khandsari Desi and Khandsari Sugar (sulfur) also known as Sulfur Sugar. It may be crystalline or in powder form. It shall be free from dirt, filth, iron fillings and added coloring matter. Extraneous matter shouldnʼt exceed 0.25 % by weight. It may contain Sodium Bi Carbonate (good grade). It shall also conform to the following standards : -! !

# Khandsari (desi) # Khandsari (sulfur)a) Moisture # # Not more than 1.5 %# # # Not more than 1.5 %b) Ash Not more than 0.7 % Not more than 0.5%(insoluble in dil HCl)

c) Sucrose # Not less than 93 %# # Not less than 96.5 %d) So2## # Absent# # # # Not more than 150 ppm

Khandsari Sugar can be distinguished from Plantation White Sugar on the following characteristics : -

# # # # # Khandsari # # # # # # PWS #

1. Conductivity 100-300 in 5% solution at 30 degree 100 in 5 % solution (10raised to 6 mho/cmsquare)

2. CaO (mg/100gm)## # Not more than 100# # # Not more than 50

Bura Sugar means fine grained sugar made out any kind of sugar. It is free from dirt, filth, iron fillings and added coloring matter. It shall also conform to the following standards : -

Sucrose - not less than 90 % by weightAsh insoluble in dil HCl - not more than 0.7% by weightSulfur Dioxide shall - not exceed 150ppm

Hard Boiled CandyThe Food Law would mean PFA (prevention of Food Prevention Act) is the central law which governs the entire gambit of food. Any good stored or sold as food has to statutory comply with the rules and regulations of this act.

1) Plain confectionary is the simplest form of confectionary. it is manufactured by cooking a mixture of sugar and glucose at a temperature of 140 - 144 degree celsius, followed by acidulants, color, flavor etc depending on the design. Then it is cooled and formed into a desired a shape in the forming machine. A moisture content of 1 % maximum is maintained to give the product the hard texture storage stability and shelf life. Examples are candy man, wild banana, mango delite, orange josh etc

2) Lacto - Bonbon :- These are also hard boiled confectionary but they contain some other value added ingredients like milk and milk products, fats and oils, fruits and nuts etc. The most important products in this category are Nutrineʼs Maha Lacto and Parryʼs Lacto King

Plain or Modified Toffee :-1) Plain toffees are a soft to chew, form of confectionary made by cooking a blend of

sugar liquid glucose and a few other ingredients like edible fats, milk, milk products, acidulants, honey, colors and flavors. The main difference between these and hard boiled candies is that these are cooked at a lower temperature, instead of the 140 degree celsius, in the case of hard boiled, these are cooked at around 120 to 130 degree celsius. Without applying vacuum, resulting in higher moisture content of about 3-5 %. It renders a product a soft and chewy texture. eg nutrieʼs Assay, Parle Kismi

2) Modified Toffee are similar to plain toffee in terms of processing and softness. The only differentiator is that it contains additionally certain value added ingredients than plain toffee. They may contain certain premium ingredients like Chocolate, coffee, cocoa, fruits and nuts. But for these additional ingredients, they are similar to the plain toffee. e.g. Parryʼs Coffee Bite, Candyman Eclairs .

Milk and Butter Toffees

Milk Toffee are similar to modified toffee, the only difference being that they are particularly rich in milk solids. The PFA prescribes a minimum level of milk ingredients. Milk Toffee must contain a minimum of 4 % milk fat, 3 % protein and 3.5 % Lactose. As you probably know, universally Lactose is found in milk. Hence a minimum level of lactose prescription ensures a minimum level of milk solids in the product. Currently there are no products available in this segment. THe fact is that there some products which can fall under this category, but no one is using this nomenclature perhaps because it is very difficult to establish whether the product does have 3.5 % lactose or not since lactose tends to convert to lactic acid on storage.

Butter toffee are also similar modified toffee, the only additional requirement is that it should contain a minimum of 4 % butter fat. e.g. candyman Butterscotch, orange Cream Licks.

Pan Goods Confectionary As the name suggests these are pan products which means that they are coated confectionary products. The coating may either be sugar or chocolate. Pouring hot syrup of sugar or melted chocolate over a suitable a center material, makes them. The center material may be chew candy or almonds or even saunf (fennel). The sugar syrup is mixed with a suitable binding agent to facilitate adherence of sugar syrup over the center material. Either hot or cold air is blown over the product to facilitate drying of the syrup. This process of coating is slow and can even take up to 4-5 hours. Products in this category are menthos, Cadbury Gems, Melody.

Lozenges They are made by cold compression of pulverized or icing sugar, under high pressure along with certain binding material and lubricants. The binding material facilitates binding of the sugar powder while the lubricant helps in releasing the tablet from the pouches. The process is similar to that of medicinal tablet. They may also contain flavors, acidulants, colors and spices. eg Minto, Polo.

Other types that are commonly available int he market are bubble gums and chewing gums. These are different from the other categories as these contain natural or synthetic latex, commonly known as rubber, which gives the product chewy and bubbling properties. Bubble gums usually contain synthetic latex which is both chewy and bubble forming while the chewing gums contain natural latex which are only chewy without bubble forming properties.

CLASS MISSED (Sorry Niketa!)

22.02.10

Food Grade Colors Used in Confectionary Industry

Class ## # # # # Color

Quinoline yellow# # # Greenish YellowErythrosine# # # # # RedIndigoline# # # # # Red and BlueBrilliant Blue FCF# # # BluePatent Blue V# # # # Blue Green S # # # # # Green and BlueFast Green FCF# # # Green

Azo Colors

Tartazine # # # # # YellowSunset Yellow FCF# # # OrangePonceau 4R# # # # # RedRed 2G# # # # # RedAzorubine# # # # # Red Amarnanth# # # # # RedBrilliant Black BN# # # # Purple and BlackBrown FK# # # # # Yellow BrownBrown HT# # # # # BrownAllura Red AC # # # # Red and YellowFast Red E# # # # # Red

Natural Colors Classification

Class! ! Coloring Extract! ! Pigmenting Substance

Carotenoids# # Annato# # # # Bixin# # # Carrot Oil# # # # Beta- Carotene # # # Vegetable Juice# # # Beta Carotene, Lycopene# # # Paprika# # # # Capsanthin, Capsorubin # # # Saffron# # # # Crocetin

Quininoids # # Cochineal# # # # Carminic Acid#Porphyrin# # Vegetable Juice# # # Chlorophyll#Betalaines# # Vegetable Juice# # # Betanine# # # Beat Powder Flavonoids# # Fruit Juice# # # # Anthocyanins # # # Grape skin extract# # #

Others# # Fruit Juice# # # # Riboflavin # # # Turmeric# # # # Curcumin

Changing of Color or fading of color

Some ingredients of confectionary, especially when associated with certain processes, may cause considerable fading of the colors. Where two or more primary colors are used to make a desirable shape, the fading of one of them may cause a complete change of color. One instance of this was a purple color that changed to a pale green when one constituent color faded completely after a few weeks.

Apart from chemical action the intensity of a color is affected by the physical condition of the confectionary. A color that appears quite bright in a straight fondant (a type of confectionary product) will lose a lot of itʼs brilliance when whipped up to occlude air. The presence of solids such as fine sugars, starches or titanium dioxide also has a deadening effect on an added color. Jellies or Turkish delight present a completely altered appearance when a chocolate covered unit is carved or beaten exposing the color center. With the uncovered piece the color is viewed through a semi-transparent medium which gives a different effect.

Example of fading of color in different media

Color# EEC # SO2 (soln)! Invert Sugar# Invert Sugar# Hard Candies# (index no.)# # # in Fondant# + light# # & Sugar/Glucose# # # # # # # # # # Fondants

Red# Ponceau 4R E 124! ! 2! ! 2! ! 1! All colors are reasonably stable ! ! ! ! ! ! ! ! ! ! if SO2 content is reduced by ! ! ! ! ! ! ! ! ! ! boiling Amaranth E 125! ! 1! ! 1! ! 1! !Erythrosine E 127! ! 1! ! 1! ! 1!

YellowTartazine E 102! ! 3! ! 3! ! 2Sunset Yellow E 103! ! 2! ! 1! ! 1FCF! E 105! ! 1! ! 1! ! 1

BlueIndigo carmine E132! ! 1! ! 2! ! 2

1 = Rapid Fading2 = light or slow fading3 = Negligible or no fading

Flavoring Materials

Classification Flavoring materials constitute a very important group of substances in confectionary manufacture and the character of many lines depends entirely on added flavoring. All flavorings, whatever their physical character are composed of highly aromatic constituents that exist naturally or are specifically selected to contribute a particular profile or subtle differences in the overall flavor of any product in which they are used. Flavoring materials include :-

1. Naturally Occurring plant material (herbs, spices, vanilla, fruits, nuts, aromatic vegetables)

2. Products derived directly from such natural materials by physical process only (extracts, essences, essential oils, oleo resins, fruit juices and concentrates)

3. Isolates or Pure Chemicals prepared from natural products (eugenol from clove, leaf oil or citral from lemon grass oil)

4. Synthetics chemically prepared from natural isolates or other natural products (vanillin from wood lignin)

5. Nature Identical synthetic chemicals 6. Artificial Aromatic Chemicals 7. Flavor Enhancers (maltol)8. Taste Modifier (salts, sugar and sweeteners, organic acid or bittering agents)9. Solvent or carrier

24.02.10

Natural Flavors

These are obtained from suitable plant sources and are generally subjected to some form of concentration before being used in confectionary products.

Fruit Flavor -The flavors of natural fruits are delicate, refreshing and pleasing to most people. Unfortunately the majority are weak and when included in confectionary contribute little of their original character to the product.

The soft fruits, strawberry, raspberry and currents contain 85-90% water and must be concentrated considerably if used as a flavor in a fondant. Concentration under vacuum is essential and even so appreciable, loss of flavor results. The modern method of freeze drying deserves the original flavor true to type but the process is costly. Concentrated fruit pulps if used in confectionary, usually require fortification with some synthetic flavor, particularly if combined with chocolate.

Essential Oils

The essential oils constitute an enormous range of aromatic materials available for use as flavoring or fragrance material. The nature and value of these are widely known but a definition is appropriate here. An essential oil is a volatile mixture of organic compounds derived by some physical process ie distillation, expression or solvent extraction from odorous plant materials. A specific oil is derived from one botanical source with which it agrees in both name and odor. Different parts of the same plant may yield essential oil of a different composition and aromatic quality. The same plant grown in different location may yield essential oil of different quality. Early investigators established that essential oils are complex mixtures of several substances, although in certain instances one main constituent may predominate (eg clove bud oil contains 85 to 90 % eugenol) The constituents of essential oils may be classified in the following groups : -

1. Hydrocarbons (C5H8)n commonly known as Terpene. Sesquiterpene (n=3), Monoterpene (n=2) and diterpene (n=4)

2. Oxygenated derivative of the above hydrocarbon3. Aromatic compounds having benzenoid rings4. Compound containing N2/S

Production :

Essential oils are all volatile in steam which means that they have a vapor pressure low enough to enable them to be distilled in the presence of water without decomposition. Being insoluble in water they can readily be separated from the aqueous distillate. Distillation in air at ordinary pressure involves, higher temperatures and in the presence of oxygen, results in decomposition of the heat sensitive components. However, many essential oils can be distilled under reduced pressure and this technique is used to prepare isolates and deterpentized oils which are valuable flavoring agents. The plant used for distillation follow the steam distillation process. The principle steam distilled oil used in confectionary include pepper mint, cassia, cinnamon, nutmeg, clove, pimento

(allspice) (because it has flavors of all spices), anise, rose. The essential oils obtained from the peels of various citrus fruits (orange, sweet and bitter lemon, grapefruit, tangerine) are not recovered by distillation, which causes serious decomposition but by hand or machine expression. Only lime oil is recovered as a by-product of lime juice production which involves boiling. The old method of hand extraction has largely been discontinued but it did yield the finest oils. The majority of citrus oils are machine expression as part of the first citrus juice operation. Special machines have been devised to ensure that the separated oil is exposed to minimum water treatment as this results in a better quality product. Some oil is recovered from citrus wastes by distillation but this is of very poor quality. The presence of excessive quantities of terpenes has a detrimental effect on the keeping properties of many essential oils. A cleaner and better flavor is obtained by using terpene less oils which are more concentrated than the natural citrus oil.

The following essential oils are used in chocolate, cocoa and confectionary :-1. Oil of Almond Origin - Kernel of bitter almonds Main flavoring component 97 % Benzaldehyde. Badly purified oil may contain small amounts of hydrocyanic acid and this is shown by high specific gravity the oil is stored in stopper bottle otherwise some oxidation to benzoic acid will occur. Uses : The flavor and the synthetic product are frequently added to pasta and to chocolate and nougat.

2. Oil of aniseed Origin - Aniseed 80-90% Anethole Currently employed, this is an attractive flavor, apart from the famous aniseed balls. It may be blended with other flavors in milk chocolate and light coatings.

3. Oil of Bay Origin - Bay leaves Main constituent - 50-70% phenolic acid Uses : Bay leaves are well known in culinary arts. Both the dry leaves and the oil used in trace amounts seem to have a synergistic effect in cocoa and chocolate.

4. Oil of Caraway Origin - seed of carumcarui Available in Holland and Central and Southern europe. Main constituent - 50-60% together with D-Limonene uses - Very useful adjunct in the flavoring of chocolates and coating. It is also used in liquors and liquid centers and in baked confectionary. Flavoring is objectionable if used in strong concentrations.

5. Oil of Cardamom Origin - Cardamom seed Main Constituent - Mixture of cineol and terpineol Uses - Blends well with many fruit flavor. The brown seeds enhance the flavor of brown coffee and this can be applied to coffee creams or coffee chocolates.

6. Oil of Cassia Origin - The oil is distilled from the bud, leaves and twigs like the Chinese Cinnamon. The bud is marketed in bails of woody dried lengths. Which are dusty to the touch and typically aromatic.

Constituent - Main component is cinnamic aldehyde 75 - 90 %Uses - Finely ground cassia bud has been used as a cocoa flavor for a very long time and the oil is frequently added to dark chocolates and coatings. Neither oil nor bud finds much use in confectionary except perhaps for some throat pastilles but both are used in cookies and cakes.

08.03.107. Oil of cinnamon Origin - The quills, as they are called ideally the under bark of the tree cinnamon zerlanicum (not important to remember the name). Seychelles and Sri Lankha.

Main constituent Bark contains about 2-2.5 % of the essential oil. The Oil varies somewhat according to the place of distillation but normally contains 60-75% of cinnamic aldehyde with 5-10% of eugenol.

Uses - Similar to Cassia but is generally considered to have a less harsh flavor. Traces of cinnamon are supposed to enhance fruit flavor and coffee.

8. Celery seed Origin - used for flavoring is usually of French origin. The pulverised seed is used as a flavoring for cocoa, chocolate and various confections such as nougats and pastes. It has the property of leaving a slightly bitter after taste. And because of this, contributes to neutralizing sickliness.

main constituent - The oil contains mainly dextro limonine. The substance known as sedonolide (C12 H 18 O 2 ). The oil of celery may be distilled from all plants of the plant but that from the seeds which contain about 3 % is considered the best.

Uses - Similar to seed, but pulverised seed is preferred for powders and the oil for confectionary.

9. Oil of Clove Origin - Extracted from Zanzibar clove flower buds. Constituent - The oil contains about 90 % Eugenol with associated esters.

Uses - Clove oil is very potent flavor. And is used in confectionary in minute amounts with other flavors, particularly vanilla. In cooking it always seems to be associated with apple dishes and could possibly be applied to some fruit flavors in confectionary.

10. Oil of Coriander Origin - Prepared from the fruits of the Russian Coriander. The plant is also grown in India and Morocco.

Constituent - The main constituent is D - Linalool which is estimated at about 70 %

Uses - This pleasantly aromatic flavor is very usefully added to lemon flavor and liquors. And as a minor constituent of Chocolate. Coriander seeds may be used as the center of dragees/comfits.

11. Fennel and Fenugreek Origin - Prepared from fruits of sweet fennel tree. Constituent - In sweet oil of fennel the main constituent is anethol. But Fenchone and dipentene are also present. The bitter oil of fennel has quite a different flavor. When anethol is practically absent thereʼs another component of Phenaldrene. Uses - These flavors have usually been associated with the true spices used in pickles and sauces. Experimental work in chocolates and confectionary products suggest that they have some synergistic action when used with other flavors and contributes to the elusive property that makes a consumer want more of the product containing them.

12. Oil of Ginger Origin - Usually manufactured from Jamaican or African Ginger. But Australian ginger has become a new source of supply. Constituent - About 2-3% of Ginger oil is obtained from dry ginger, dried rhizome and the main contents are dextrocomphene and B - Phellandrene.

Uses - The ginger oil is mainly used for hard boiled confectionary product.

13. Oil of Lemon Origin - Lemon grass Constituent - D Limonene Uses - Lemon oil probably has a greater use in confectionary than any other essential oil and because of the enormous demand. The natural product is frequently sophisticated.

Keeping properties - Lemon oil will deteriorate as a result of auto oxidation if exposed to light and air and develops a turpentine like flavor. This may be retarded by the addition of an anti-oxidant.

14. Oil of Orange Origin - There are two varieties. Oil of sweet orange derived from the tree Citrus Sinensis and the bitter oil from Citrus Aurantium Amara or Citrus VulgarisConstituent - 90 - 95 % D-Limonene.Uses - Orange oil is probably second to Lemon oil in itʼs use in confectionary. Bitter oils are often used in cream centers with dark chocolate coating in preference to sweet oils.Keeping Quality - Orange oil is very prone to deterioration particularly in aerated confections, such as marsh mallows or a fondant coating Egg Whip. The oil itself will also deteriorate rapidly if exposed to light in the presence of air and storage in cleared bottles partly filled will result in the development of a Resinous and Caraway type of flavor.

15. Oil of Peppermint origin - This is increased in popularity, probably due to a great deal of research into the growing of various stems of the plant and in the distillation and rectification of the oil. The peppermint oils in the market today are a variety of blends and for confectionary purposes. That have a smooth floral bouquet are most popular. True peppermint oil is distilled only from the fresh plant Mentha Piperata.

Constituent - L-Menthol # # # # # # 50-65%# # Menthone # # # # # # 9-19%# # Menthyl Acetate and isovalerate 5-15%Uses - peppermint oil is used for specific type of confectionary. Best known are peppermint patties. Sometimes crystallised, clear mint, glassy, high boilings, mintos, peppermint crisps usually aerated high oilings and compressed mint tablets.

CocoaIt is not native to India. Main cultivators are Amazonian area, Africa, Ghana, ivory coast, Nigeria, brazil, Malaysia, Sri Lanka and very less amount in Karnataka and Kerela.Cocoa is theobromo cocoa linn. Four to eight years are required for the growth of the plant. Optimum temperature for growth is 45 to 48 degree Celsius. Good rainfall is required. Soil condition should be good with good amount of mineral content. Wind is the greatest enemy in the production of the plant. Productivity lowers in shade. Each plant contains 25-40 beans arranged in a row. World production is from 8million tones. Indian production is only 5000 tones. India imports 1000 tones annually to prepare various cocoa based products, health drinks and chocolates. Products are reexported to Pakistan and Bangladesh.

Natural varieties are Criollo, forastero.Criollo - good flavor and color. Yeild - 91-318kg /acre. Yield is less but quality is good. Only 5-8% of the total production of the world.Forastero - medium quality. Yield is more. Amazonian area is the main cultivator. It gives 454-2268kg per acre. It has 25% disease resistant properties.

Another variety is Tinitario - it is a hybrid variety. Combination of criollo and forastero. It is disease resistant and gives good yield and medium quality.

Processing:Flow chart from Raman.

FermentationHeaping the beans - covering with leaves of the same plant - so chemical, microbiological and enzymatic changes occur (purpose to remove adhering pulp, mucus, kills germs, modify color flavor of bean, so t will be easily breakable.

Fermentation time forcriollo varieties - 2-4 days. 25-30 degree.Forestero - 6-10 days, 25-30Tentaeio - 4-10 days. 25-30

Sun drying or mechanical drying can be carried out at 45 to 50 degree celsius. Where final moisture content should be 7%

Better flavor is obtained in sun drying. Fermentation and drying alters seed coat and change to rough skin and dried skin which can be easily removed.

Cleaningis done by counter current air flow and magnetic separation to remove light particle and insect infestation of bean. Irrespective of the type of equipment chosen for roasting beans need to be cleaned before they can be processed to remove all foreign object from cocoa meal. Clean products are not only required for product safety but these impurities can also cause wear and tear and damage to the machine.Cleaning is usually carried out I'm several stagesRemoval of pores and fine by sievingRemoval of ferrous metal by magnet

De-stoning and removal of other high density particle by gravity separationDust collection during several cleaning steps

A Set of screens remove both very large and very small particles by seiving. Cluster beans, pieces of wood and strings and other large debris are collected by coarse screen which cocoa bean pass through. Smaller particles are then allowed to pass through fine screen. Broken beans are often removed as the broken seed cotyledon (nib) will quickly deteriorate.once exposed to air and humidity. The beans are then transported usually by falling under gravity to the next step in the cleaning process. As the beans fall a counter current air flow aspirates low density and dust particle. The ferrous material is then removed by magnets in a rotary drum. The cocoa beans are then spread out over a rotating stainless steel drum jacket and even flow and controlled depth of the bean layer is very important in obtaining a clear product. On the side of the drum, a stationary magnet which attracts a ferrous material so that they are retained by the drum. As the drum turns, the particles come to the non magnetic zone where they become detached from theDrum and fall into the metal recipient. Metal detector with inject mechanism which interrupts the flow of beans and remove the ferrous material. Destined removes stones and other heavy particles. They operate on the principle of fluidized bed. Air passes through an oscillating, inclined screen and then through beans that are on the top of it. The heavy particles rest on the screens d oscillates towards the top of screen from where they fall to s stone collecting bag. A cushion of air transports the beans towards the lower end of the screen where they fall to the next screen. Dust is collected and separated by suction on the end of the process and the other particles are removed with this dust as sand particles are extremely abrasive in fine roll, refiners as well as dust contains wide variety of biological and chemical contaminants. The chocolate manufacturer receives 20-25 tones of green bean in bulk amount and is discharged into the field system of the factory site.

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31.03.10RoastingRoasting is carried out in an open flame heating, gas heating, electrical heating, hot air or infrared heating. Changes during roasting

1. Development of flavor2. Textural changes so that it is easily breakable3. enhances cocoa taste4. Color development5. Removal of water6. Few chemical changes carried out at 115 to 140 degree celsius for 40 minutes, 200 degree for 20 minutes or 110-115 degree for 60 minutes.

Traditionally the chocolate industry roasted whole beans. The broken D shaped cotyledons of cocoa beans are generally referred to as nibs. However over the past few decades nib roasting has become increasingly common. Raw liquor roasting offers an alternative to these methods. All three systems can be used by chocolate manufacturer to obtain good results. The definition of the word Good may however differ from manufacturer to manufacturer. Certain trends can be identified. In UK, crumb is often the basis for milk chocolate production in which a medium type roast is normally used. In Germany, the consumer demand is for milk chocolate with a very mild cocoa flavor and a strong milk flavor which requires a lightly roasted cocoa liquor. In USA, a more pronounced roast is generally preferred.

Whole Bean Roasting It is the original method of roasting. The removal of shell after roasting is easy, as the shell becomes loose during roasting. When the nib is sufficiently ground, the cocoa butter is liberated from the shell structure. This leads to a fluid product, when it is kept at a temperature above the melting point of cocoa butter. This product is referred to as cocoa mass or cocoa liquor. The volatile components of the cocoa flavor are well preserved during whole bean roasting because the same acts as a barrier. This makes whole meal roasting suitable for both the delicate flavor of fine grade beans and the preservation of the top components of low and medium roasted cocoa.

For this type of roasting, it is the utmost importance to have equally sized beans. As smaller beans tend to be over roasted as larger beans are under roasted. The problems caused by abnormal bean sized distribution are particularly noticeable with whole bean roasting. However, even with the graded beans flat and other rod shaped beans will be roasted differently from more regularly shaped beans. During whole bean roasting a slight loss of cocoa butter will occur, due to migration into the shell. This reduces the yield in comparison with other roasted methods. Usually, 0.5 % loss of cocoa butter will occur. The over all amount of energy required is also less favorable, for whole bean roasting for the following reason :-

1. The larger specific surface of the leaves and certainly that of the liquor, enables their shorter and lower heat treatment to be used for the same flavor.

2. The shell is no longer a heat barrier, nor does it need to be heated itself. 3. both these factors increase the over all capacity of the roasting equipment when

comparing nib vs whole bean roasting.

Nib Roasting

Removal of the shell of the bean is pre requisite for nib roasting. Some beans can be de shelled, relatively easily as for example the well fermented and properly dried beans. Several system of thermal treatments exist. These treatments are usually followed by a separate heat treatment to reduce the microbial contamination of the product. Although roasting already leads to a massive reduction in micro organism, a separate heat treatment of leaves prior to roasting will give the lowest plate count results. Nib roaster exist both as a continuous air roaster and as drum roaster. Drum roasters are often of the batch type. Batch drum roaster are used to preserve the top flavor components. Whereas continuous air roasters are commonly used for West African Cocoa Bean type.

Liquor or Mass roasting

When the bean particles have been reduced in size, the cocoa butter is set free from the bean shells, and the product becomes a paste. This raw, un roasted liquor has a better homogeneity of particle sizes than the product obtained using the methods described above. In order to achieve this, the product has to de-shelled as with nib roasting and the moisture content must also be reduced, from the initial 7-8 % to 2%. This can be achieved by combining drying with the heat treatment used, prior to de-shelling. Alternatively, drying of the leaves or special milling techniques can be used to make the liquor sufficiently fluid for it to be roasted. Thin film heat exchanger, with or without scrapping devices that can be used for this purpose. Often the same type of equipment is used to de-gas or de-acidify the roasted liquor.

Removal of shellRemoval of shell is an important step in the process of making cocoa mass. Beans are generally broken by impact crusher. Centrifugal force is used to break the beans against an impact plate and then they fall out of the breaker. Before breaking, some pre treatments are required. 1. Simple pre-drying of the leaves - For instance in a narrow channel dryer, similar to the

ones used for continuous roasting.2. Steam puffing process - In this the beans are heated with saturated steam and

subsequently dried. 3. Surface heat Treatments - During which cocoa beans are heated on the surface by

infrared radiation.

Principle of breaking of the beansBeans are passed through a roller and air is also passed through. A lighter particle separates, due to breakage of shell. Shell and nib shell mixture is obtained after winnowing. Germ separation occurs in the shell side.

Germ free leaves passing through mill - fat melts at that temperature so that ground nib gets liquid consistency, about 55 % fat. Sometimes a second impact stage is built into the design. After the first impact plate, unbroken beans fall into a second rotating wheel that swings the beans back against the impact lid. The centrifugal force of the wheel and throughput determine the particle size distribution for a given quality of beans. This distribution should be as homogeneous as possible and contain a minimal number of particles, smaller than 1.5mm or bigger than 7mm. A sieve is usually mounted before the breaker to remove broken beans that are already small to prevent them from being broken, further into particles that are too small. Un broken beans in the outlet product are returned

to the breakers. The particles produced are very abrasive and considerable wear of the machinery takes place. It is important therefore that the equipment is designed in such a way that parts such as impact plate can be easily exchanged. Shell is mainly thin and plate like. It is easily blown upwards by a stream of air whereas a spherical nib particle of a similar size will fall under particle. Each shifter has itʼs own optimal air flow, which depends on the size fraction being treated. The smaller particle size the more difficult the separation between shell and nib.The number of sieves and air classifiers depends on both the pre treatment of the beans and state of the operation. Several types of roasters are available : -

1. Continuous Air Roaster2. Batch Roaster3. Thin Film Roaster

High fat chocolates contains 20-25 % fatMedium fat chocolates contain 10-20% fatLow fat chocolates contain <10% fat

Cocoa Manufacture

Alkalination

Removal of Excess Moisture

Pressing (7000 kg/m square)

Press Cake Cocoa Butter

Breaking

Grinding

Sifting

Cocoa PowderCocoa Mass

Addition of sugar, flavor, milk cocoa butter

Mixing (Merangering)

Refining (Type of mixing)

Tempering

Moulding Enrobing

VIKRAM (6.04.10)Table Vikram

Pressing or grinding is done by disk pulverizer or micro pulverizer. Pressure maintained is about 7000 PSI. In multiple pulverizer 20-28 % cocoa butter is present. Breaking or grinding is carried out In revolving plate. Passed pulverization multiple set of pulverizer. after grinding cooling is done  to reduce temperature 22-23 degree otherwise it may form aggregates. After sifting is carried and passed through mesh. Storage temperature of cocoa powder is 18-20 degree centigrade and relative humidity 50-60% moisture should not exceed 4 percent. Density is 1.39g per cc.Quality of powder depends on pH, fat, moisture, particle size, color, flavor and bacteriological tests.

Reduction of micro organismsCocoa mass used for chocolate must be free from pathogenic bacteria. If the cocoa nibs that are used to make liquor are properly roasted and if no post treatment contamination occurs then they'll be free from such micro organism. A residual plate count of 2*10 to the

power 4 per gm is low compared to many other foods and is quite acceptable in an exclusively chocolate environment.  Where the low moisture and high sugar condition make growth impossible. New applications of chocolate are commonly found eg combination of chocolate with dairy products. This demands stricter bacteriological specification for high moisture environment.

1. Buhler has developed a special steam treatments screw that can be used for nibs.

2. In drum roaster water and /or steam addition is proposed as an additional micro organism reduction step in the process before the actual roasting. In the most recent versions of the Barths a separate reactor is recommended just before the roaster.

3. For liquor roasters, separate pin fin columns are proposed. The un roasted liquor is mixed with a static roaster. Theraw liquor is exposed to about 1 minute to temperature between 130-140 at 2-3 bar pressure and reduce temperature immediately. Reduction rate factors of 10 to the power 4 have been observed.

Refining:3-5 roll mills are employed. It gives a fine grinding. Materials are passed through closed clearance requiring roller and particle size of material cast is 25 micro meter or less. So crystallization is prevented.

Effects- crushing, attrition, abrasion, shearing or cocoa and sugar, desired particle size is reached. Mixture becomes flaky powder.

Fat bloom -Is possible due to presence of different tri glycerided there is a chance of separation of fat crystals. This is fat bloom.

Conching:

Mixture is conched (roller within a curve tank) kneaded in special heated mixing tank fitted with pressure roller that grind and aerate the melting mass to develop smoothness, flavor, color to become less viscous. For emulsification of fat. Removal of sugar crystals, removal of moisture is required. Temperature of conching is 60 degree and time is 96-120 hours. This step essential for high quality chocolate making.Oxidation of sugar, caramelization, development of color and flavor.

Chocolate may contain a lot of tri glycerides of different boiling point. So there is chance of uncontrolled crystallization of sugar and fat. (Sugar bloom and fat bloom). To get uniform crystallization, tempering is necessary. Following conching liquid chocolate is tempered by being stirred in a heated and cooled kettle. The objective here is to melt all the tri glycerides of the fat and the. Initiate uniform crystallization of different try glyceride fraction. Tempering condition may vary but usually the mass is melted at 54degree and followed by controlled cooling at 32 degree with continuos stirring for about 1 hour to get uniform mass. Then it is placed at a mould  16 - 18 degree and 60% RH so that you can get good chocolate. Migration of fat in chocolate is possible so aging is necessary for 6 months. Enrobing of liquid chocolate - solid i.e. mass moulded for long term storage -10 to -20 degree of liquid chocolate. Main characteristic of chocolate is that it melts at mouth temperature.

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07.03.10Flavor development

The flavor of a piece of chocolate depends on a series of processes being carried out correctly. Conching is the final one of these processes and is the last opportunity for a manufacturer to obtain the taste required for a particular product. it cannot however correct previous flavor off flavors from smoke and mould arising from poor drying, nor can it make an inferior cocoa taste like perfect. The objective of conching is essentially the removal of undesirable flavors and in certain circumstances the development of more desirable ones to match the final product. The former is particularly important for dark chocolate and is largely dependent on conche (instrument for conching) ventilation and conching time. The development of flavor in milk chocolate will also depend on the ingredients being used. Those manufactured from milk powder maybe heated to obtain a more cooked flavor. Whereas those starting from cocoa crumb, already contain a cooked flavor. Although this can be strengthened during conching. This type of flavor development depends on the conching temperature and time.

Conching can be divided into three phases or stages although not all occur for every recipe and for all type of conching.

1. Dry Phase2. Pasty Phase3. Liquid Phase

Dry PhaseChocolate mass is crumbly, Moisture is removed.

Pasty PhaseChocolate is a thick paste, high work input required by the conching.

Liquid PhaseHigh speed stirring to mix in the final fat and emulsifier addition.

Figure from Vikram

Graph showing the changes in conche amperage, water and chocolate mass temperature during conching cycle.

Dry phase conchingThe feed material normally enters the conche as a powdery material. Frequently a small amount of fat, approx. 1 %, is placed in the conche at the beginning of filling. This together with a mixing action and rising temperature soon turn it into a crumbly mass. At this stage it is relatively easy for moisture to escape, provided that the conche is well ventilated. These initial moisture content of many milk chocolate is about 1.6% and if possible this must be lowered to less than 1 % For dark chocolate, the initial moisture may already be below 1% and care must be taken to avoid the chocolate picking up moisture and becoming thicker. It is very undesirable to conche, dark and milk chocolate in the same room in open conches because the transfer of moisture and flavor volatiles between the

two can give rise to unpleasant flavors and thicker dark chocolate. The temperature must of course be increased slowly to enable the moisture to escape and minimize the risk of formation of agglomerates. In the above diagram, as the filling progresses, the electrical current drawn by the conche rises and continues to increase throughout the dry conching phase. This is because the crumbly chocolate is becoming more pasty. This often starts with the formation of small balls 1-4 cm diameter, on top of the mass. Sometimes large lumps attach themselves to the mixing elements as the mass becomes more pasty and in exceptional circumstances the whole mass can turn with the elements resulting in no mixing taking place. This can be offset by changes to the temperature and/or fat content. In certain conches the motors are not sufficiently strong to continue operating as the power increases. Fat and emulsifier additions are made very early in the conching cycle to turn the chocolate mass into a thin paste or liquid. In this case there is little or no dry conching normally. However, this results in a relatively high viscosity chocolate at the end of processing.

Pasty Phase conching The energy put into the chocolate by the mixing action towards the end of the dry conching and the beginning of the pasty phase is often so high that the temperature rises rapidly. The water jacket temperature, therefore has to be several degrees lower than the chocolate in order to maintain a steady increase to the required conching temperature. This has a large effect on the final chocolate flavor and so must be controlled carefully in order to produce a reproducible product. This is particularly critical during the pasty phase when thermostatic water jacket controls, capable of reacting to sudden temperature changes should be used. Once the chocolate has become pasty, the viscosity starts to fall in part because of continued moisture removal and also because many of the solid particles are now being coated with fat. Actual final viscosity, however is partly dependent on amount of shear or work that can be put into the chocolate. The shear energy input (as denoted by the conche amperage) falls strictly as the chocolate becomes thinner. This can only be offset by increasing the shear rate. This can be achieved by increasing the speed of the mixing elements or conching the element themselves.

DIAGRAMs (3) from Sunil

The above figure shows the power curves of a conche that has been fitted with a servo that changes the speed as the viscosity changes to give a uniform power input. In order to develop a cooked flavor within a chocolate, it is necessary to reach a certain temperature for a given time. Within limits it is possible to raise the temperature and shorten the time and vice versa. The same is true for conching power input and if the power is increased, shorter conching times are possible. Once the final addition of fat and emulsifier has been made, however the Chocolate becomes very thin and it is very difficult to put a further amount of shearing energy into the chocolate.

Liquid Phase Conching This phase can be very short and is required to mix. In the final recipe additions, sufficient time must be allowed for the viscosity as there is little change in flavor for additional work input, however there is little reason for extending this stage. When conching at a high temperature, additional time may be required to enable the chocolate to cool before the emulsifier is added. Lecithin is less efficient when added to chocolate hotter than about 60 degree celsius. The conche is the last major processing stage before the chocolate is used for moulding, enrobing etc. This process requires a consistent viscosity and power adjustment may be required. One approach is to place a viscometer in the discharge pipe from the conche and then make the necessary fat and emulsifier fat in the storage tanks.

An alternative solution is to monitor the conche electrical power curve and use these to make fat adjustment into the conche during the liquid phase. The viscometer can be fitted inside the conche. This operates by measuring the damping of mechanical oscillations that can give continuous readings which are recorded by the computer control system.

The chemistry of flavor development in chocolate in different stages of unique flavor. The mix and balance of the numerous compounds that contribute to the final flavor depend on genetics. Environmental conditions harvesting and processing. With the chocolate the chemical complexity of flavor development is evident when one realizes the numerous parameters that may influence it's development.

1. FermentationOnce cocoa is harvested, biochemical mechanism that contribute precursors for development. Even though the fermentation process facilitates the removal of the mucilaginous pulp and prevents germination of the bean. Cocoa shells cultures only the shells have matured could a chocolate or cocoa flavor results from further processing. Prior to fermentation structural changes along with protein hydrolyses in cocoa seeds is observed. Fermentation is required because unfermented beans may develop little chocolate flavor when roasted. Excessive fermentation may also result in unwanted flavors. In early fermentation the major sacchiride is sucrose, however it is soon hydropower into glucose and fructose as fermentation progresses. During hydrolyses reaction, the fructose content increases as compared to glucose after approximately two days of fermentation. Following the fermentation the beans are dried, and this is also instrumental in flavor precursor development. Indicator of good drying practice relating to flavor quality of the beans are good brown color and low astringency and bitterness. Freedom from off flavor such as excessive acidity and smoky flavor is also indicative of proper drying. It is during the drying phase of cocoa curing that the characteristic brown color of chocolate develops. Major oxidizing reactions occur with polyphenols catalyzed by the enzyme polyphenol oxidase. The death of the bean, with loss of membrane integrity allows previously restricted enzymatic reactions in brown colored formation. Excessive heat and rapid drying may not allow for adequate loss of the volatile acids as for example acetic acid and therefore have a detrimental effect on quality. There also may be situations where the water activity within the bean is such that the drying process is merely a continuation of the fermentation process and many reactions can proceed. A high level of water activity as a result of incomplete drying or rain soaking may also recur in mould contamination. This is particularly noticeable for beans in transit. High concentration of strongly flavored carbonyls may result from heavy mould growth and thus alter in flavor. Total carbonyl may double in concentration in mono carbonyls increasing by 500% and methyl ketones exhibiting a noticeable increase.

Diagram!

Roasting:

Roasting reduces the acidity as evident by the significance decrease in the concentration of volatile acids especially acetic acid which reduces the acidic taste. The concentration of non volatile acids as for example oxalic, tartaric, succinic and lactic acid are not influenced by roasting. After roasting the beans posses the typical intense aroma of cocoa. The Roasting process normally heating the beans from 110 to 220 degree. Depending on wind type, is needed for the reduction of moisture, release of the beans from the cell and development of chocolate flavor. One of the most important and complex reactions

involving flavor during the roasting process is non enzymatic browning, mallard browning or carbonyl amine reaction.There are three stages of reaction : initiation, intermediate and final stage. One of the key reaction is the rearrangement of the  glycosylamines (reaction product of reducing sugars and amino acids produced from additional compounds) into isomerization products.

Conching:If the flavor change caused by conching is simply due to the coating of the particle with cocoa butter then controlling the particle size might allow for maximum conching efficiency because large particles require less cocoa butter per unit for coverage, the larger particle might be easier to conche. It is important to consider the range of particle size. The mouth determines to be gritty and also size range necessary for minimum cocoa butter used.

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13.04.2010

Enrobing and Moulding

Two major distinct forms of sweet making exists enrobing and moulding. In the first, the chocolate is poured over the sweet centre, with any excess being removed by shaking or blowing. In the second, it is poured into a mould where at least part of the chocolate is allowed to set.

Components of Enrober

The above figure shows the basic component of an enrober. An enrober consists of a driven wire grid conveyer belt (1) on which to transport the centre to be coated. This passes over a stirred reservoir tank (2) which holds the tempered chocolate. A chocolate pump (3) circulates the chocolate up. A riser pipe (4) and into the top flow pan (5). The flow pan creates one or two curtains of chocolate through which the uncoated centers pass. Positioned below the top flow pan and beneath the grid is a bottoming trough also called surge roller trough. This trough retains chocolate falling from the curtain and feeds it onto a flat plate. Thus forming a bed of chocolate that moves with the wire grid. The centers entering the enrober are semi - suspended by this bed and become coated on the under side. An air nozzle (7) is located after the chocolate curtain together with a grid shaker frame (8). A number of grid licking roll (9) are shown located after the grid shaker. These remove excess chocolate from the grid and product. Any chocolate drained from the roll scrapper is returned to the reservoir tank. Higher the grid belt running along a heated extension trough (10). The coated sweets, leaving the enrober pass over the Anti-tailing rod which as itʼs name suggests, controls the tails or residues left by the liquid chocolate as it separates from the wire grid and transfers into the cooler belt or plaque.

Chocolate panning The definition of pan coating may best given as follows - Pan Coating is the built up of a center (kernel or corpus) with a liquid or liquid and powder substance with multiple layers or continuous phases, which are set, hardened and dried to a smooth or pearled surface and often finished with a sealant and/or a polishing agent, utilizing rotating pans or drums, creating a fluid bed. The machinery used is often compared visually with a cement mixer. The drums or pans are horizontal or have their front slightly elevated and are fitted with internal ridges which are used to aid mixing. As the product mixes, thin layers of liquid are added to coat the center material. It is during the drying or setting of this coating that the tumbling action causes the surface to rub against each other to form a smooth finish. Care has to be taken before marketing the products made by panning because some countries have standards covering pan coated goods and it is always advisable to check local laws and regulations. Frequently panned goods are named by their centers and/or shell applied to the confectionary. e.g. an almond center with a chocolate shell would be called as Chocolate Almond.

Chocolate Panning - Chocolate panning is a temperature depended method in which the coating solutions are melted under the influence of heat and hardened again by the removal of heat. Several layers of warm, melted coatings are applied to the centers and solidified by cooling. Chocolate panning is probably is no longer the most accurate name for this process because although chocolate is still the pre dominant coating medium compound and Yoghurt coatings are fast gaining popularity.

Steps :-1. Center Selection2. Center Preparation 3. Coating Selection (largely dictated by marketing requirement)4. Engrossing (which involves a) building the base with chocolate or other compound, b)

rapid weight gain and c) smoothing)5. Polishing6. Sealing7. Packaging

Packaging Materialsa) Aluminum Foilb) Regenerated Cellulose Filmc) Paper Board/ Wax Coatedd) Plastic Filme) Cold seal

Quality Control for Packaging Material

Packaging material should be capable of passing the following tests -

1. Seal Strength2. Tensile Strength3. Bursting Strength4. Co-efficient of Friction5. Moisture Vapor Resistance6. Detection of Residual Solvent7. Print Stability8. Resistance to Abrasion9. Scannability of Bar Codes

Product Definition

Chocolate Min 35 % Cocoa dry solidsMin 18% Cocoa ButterMin 15 % dry non-fat cocoa solids

Milk Chocolate 25% Total Dry cocoa solidsMin 14% Milk or milk productsMin 2.5% Dry non fat cocoa solidsMin 3.5% Milk FatMin 25% Total fat

Milk chocolate with high milk content Min 20% dry cocoa solidsMin 20% Milk or milk productsMin 2.5% Dry, non-fat cocoa solidsMin 5% Milk fatMin 25% Total fat

White Chocolate Min 20% Cocoa butterMin 14% Milk or milk productsMin 3.5 % fat

Filled Chocolate, chocolate with filling of center, minimum 25% by weight of specified chocolate product. This is chocolate product definition under PFA.

Sugar Boiled ConfectionaryMany confectionary processes utilize the special solubility properties of sugar (sucrose) alone or combined with other sugars such as glucose syrup (corn syrup and invert sugar). There are basically two groups of sugar confectionary products.

1. Those in which the sugar are wholly in solution2. Those in which the sugars are partly in solution and partly in the form of minute solid

sugar crystals suspended in the solution. Other ingredients such as milk and fats may modify these products.

Group 1 includes hard boiled sweets (hard candy, hard and soft caramels and toffees and most jellies) Group 2 consists of products such as fondants, fudges, grained marshmallows and grained nougats.

It can be seen that a variety of textures are obtained as a result of various processes and formulations and each requires a particular method of forming into pieces or bars. Different parts of confectionary processes :-

1. Rolling and Cutting - THis is probably the oldest method of producing bars and pieces. Mostly from plastic products like caramel, nougats and various pastes. The confection in the right plastic condition, because of either itʼs moisture, fat content or temperature is first fed through a roller to produce a slab of the required thickness. The slab is then fed to knife cutter to produce wide strips that are subsequently cut into narrow bars or small units. In a modern development of this principle the hot product is fed to iced roller enabling the production of multiple layer slabs. The slabs are continuously cut into strips that pass over a spreader and are then cut into Bars or small pieces.

2. Casting or Depositing :- This method is applied to hard candy, fondant, some caramel and fudge, marshmallows and other products that can be obtained in liquid state.

a) Hard candy - Certain types may be deposited as liquid at around 150 degree celsius into metal moulds, the surface of which are coated with a release agent (like grease, or glossy)

b) Fondants, Jellies and Marshmallows - These are usually cast into starch moulds. The more recent developments have been automatic depositing and release of fondant and some other confections from metal moulds. The depositing of caramels and toffees into silicon-rubber moulds. Silicon-Rubber has unique non stick properties as well as being resistant to the relatively high temperature of high boiled confections.

3. Die forming :- This method is applied almost exclusively to hard candies and some caramel and toffees. It includes normal, flavor pieces, filled pieces (bon-bon). The principle is to cool the boiled syrup under controlled conditions until it is plastic. In this state it is reduced to a rope which is fed to machine dies that presses the rope into pieces that usually have some special form or pattern. This pieces are immediately fed to a cooler and a wrapping machine. A modification of this principle is applied to certain caramel and chewy candy. Here the rope is similarly produced but it is fed to a cut and wrap machine which by means of high speed rotary knife cuts small pieces of the rope. These are fed to the wrapping machines.

4. Extrusion and bar forming :- The principle of extrusion developed for many non-food products has been applied very successfully in the confectionary industry for the manufacture or variety of products ranging from soft materials such as marshmallows and fondants to very plastic nougats and caramel. In the process the material to be extruded is fed to the orifice by means of multiple rollers or screws. The cross-sectional area of the orifice determines the shape of the final movement and many

extruders have a series of orifices producing ropes that can be cut into either bars or small pieces. Multiple bars can be made in which two layers are extruded simultaneously. Alternatively a bar with a center of a different confection can be made. Extrusion allies itself to other continuous methods of cooking and enrobing. Certain precautions must be observed in the manufacture of confectionary : -

1. Temperature2. Fat Separation3. Collapse after extrusion

1. Temperature : The temperature of extrusion is critical,particularly with caramel and nougat where texture is closely related to temperature and quite small changes can cause large differences in extrusion pressures for a very soft caramel, temperatures ranging between 35 to 38 degree celsius are usual, but obviously a lot depends on the type of product and the exact conditions must be determined by trial. Low temperatures and high pressures will cause the safety plugs usually provided on extrusion machines to be ejected.

2. Fat Separation - If fat separates during extrusion, it is an indication of poor emulsification. Improvement is obtained by the inclusion of an emulsifier such as lecithin or preferably glycerol-mono-steareate in the recipe .

3. Collapse after extrusion - Some products lose their shape after extrusion and a strip of near cylindrical cross sections may flatten appreciably after it has been on the belt for a short time. There are several reasons for this -

a) The moisture content is too high.b) The fat has not been emulsified and possibly is too soft.c) The protein of any milk ingredient is not properly dispersed.d) In fudges or pastes the crystal structure has not formed or may have broken down by

excessive mixing after forming the crystals. This can be a very elusive defect and in continuous fudge manufacture and is related to the time at which the crystallizing fondant is added prior to extrusion. Only experiment will determine the optimum conditions for particular equipment. Companies specializing in extrusion equipment have done a great deal of research into the design of machines for extrusion of confections of different consistencies. For some products such as chewable candies and chewing gum the roller extruder has given way to the multiple screw extruder.

FIGURE FROM VIKRAM

Taru! LakhanpalB.E. Food Technology (Year 3)

CH-7714University Institute of Chemical Engineering and Technology

Panjab University, Chandigarh